Dyed composite felt and method of making same



Patented Oct. 14, 1947 SAME George M. Rickus, Stanley G. 'Hofl'man, andBernard H. Archer, Norwalk, Conn., assignors to Eat Corporation ofvAmerica, Nor-walk, Conn., a corporation of Delaware No Drawing.Application August 5, 1944, Serial No. 548,320

11 Claims. 1

The present invention relates to improvements in dyed felt fabrics orhats embodying nonanimal fibers therein and particularly to thetreatment and use of nonanimal fibers in mixtures with animal fibers,which nonanimal fibers are center-seeking and receptive of acid dyes.The

term nonanimal fibers is used herein to describe vegetable fibers suchas cotton, jute or the like and synthetic fibers such as viscose andacetate rayon or the like.

The present invention is an improvement on the invention disclosed inapplication Serial No. 433,622, filed March 6, 1942, now Patent N0.2,355,598, granted August 8, 1944, wherein the treatment of cotton andother nonanimal fibers to render them center-seeking is disclosed andclaimed.

In the priorv process, diificulty was encountered due to the fact thatcotton or other nonanimal fibers did not readily take the acid dyerequired to dye animal fibers. Thus, in places on hats or the like wherethe animal fiber on the outer surface is thin, the poorly dyed cottonbeneath showed through and presented a mottled appearance.

, To overcome this, center-seeking fibers were dyed, before mixing withfur, with a fast color to the exact shade of the finished hat in whichit was to be used so that it would not be noticeable through the thinfur.

Since the center-seeking fiber could only be used in hats of theparticular color for which it had been dyed, it required a vastinventory of differently colored fibers to take care of theshades ofhats normally manufactured in the course of the season.

The present invention overcomes these difiiculties by providinga treatednonanimal fiber which has an afiinity for acid dye and which may bemixed with animal fibers and dyed therewith. This is accomplished byproviding the nonanimal fibers with a coating of melamine-formaldehyderesin which is insoluble in water or acid at tem- 'peratures up to 212F. Fibers so treated may 2 e Other features and advantages willhereinafte app a The invention will be described as applied to themanufacture of fur felt hats and cotton will be used as the nonanimalfiber. It is to be understood, however, that this is by way of exampleonly and that other animal and nonanimal fibers may be used as required.

In the manufacture of fur felt hats, the mixture of fibers is depositedon a cone and then subjected to hot water and pressure, the temperaturesof the water being substantially at boiling point to cause fibers in thebat to felt and produce the hat body.

Furthermore in dyeing the hat body, it must be boiled in an acid dyesuitable for dyeing fur for a period of one-half hour to an hour andonehalf. Hence, in order to find a composition for treating thenonanimal fibers to render them receptive to acid dyes, the usualmaterials for assisting the dye afiinity of the cotton fibers could notbe used for these were either soluble in water at high temperatures,soluble in. acidat high temperatures, or lost their aflinity for dyewhen dried and set at high temperatures.

According to the present invention the cotton fibers are renderedreceptive to acid dye by ime pregnating them with an aqueous solution ofmelamine, formaldehyde, a softener such as Ciba Finish 603 Powder(aliphaticaminoethylamide) and an accelerator such as hydrochloric acidand properly aged. The aging of the solution is essential in order toobtain a coating which will be insoluble in water and acid as required.

After a thorough treatment with this composition, the fibers have amelamine-formaldehyde resinous coating thereon. The fibers are dried athigh temperatures of between l-200 F. to set the coating on the fibers,after which the coating is insoluble in water and acid at temperaturesup to 212 F.

The impregnating solution may contain 2-10% by weight of melamine, 4-9%by weight of hydrochloric acid (32%), 440% by weight of formaldehyde(35-40%), .52% by weight of Ciba Finish 603 Powder, and the balancewater. The solution must be properly aged before the cotton isimpregnated.

It is believed that one example of the use of the foregoing compositionwill be suflicient to make the invention clear. Combed cotton fibers areprepared for treatment by thoroughly cleaning and/or scouring them toremove all surface dirt and oil, grease and cotton wax. If the cotton isto be used with white fur, it is now ready for treatment. On the otherhand, if it is to be used with gray fur or tan hares fur, it is dyedgray or tan to match the natural color of the fur with fast colors, suchas vat dyes, sulfur dyes and the like. It will be seen then that only afew colors of cotton will be necessary for all colors of hats made in aseason. Under some conditions, the treated white cotton can be blendedwith any of the above furs to producea satisfactory hat.

The cotton fibers are then treated with a solution comprising 5%melamine, 6% hydrochloric acid (32%). 8% formaldehyde (35-40%), 1% CibaFini h 603 Powder. and the balance water, which we have found to beparticularly effective. It is essential that this solution is aged forat least twelve hours before being applied to the fibers. If morehydrochloric acid is used, the reaction is accelerated and the agingperiod is substantially lessened and if less is used the aging period isextended. The cotton fibers are thoroughly impregnated with the solutionand have a melamine-formaldehyde resin coating thereon. They are thendried at a temperature of 195 F. to set the coating which becomesinsoluble in water or acid at temperatures up to 212 F.

As the cotton fibers are treated with the solution. the hydrochloricacid in the solution as an accelerator for the melamine and formaldehydeacts on the cotton and simultaneously renders it center-seeking whenmixed with fur as described in said copending application.

The treated fibers are cut to short lengths and are thoroughly mixedwith fur fibers in the proportion of 60% fur fibers and 40% cottonfibers (this proportion may vary as required). The mixed fibers aredeposited on the forming cone and subjected to hot water atapproximately boiling point and pressure to form a felted hat body inwhich the fur fibers are on the exterior of the felt and the cottonfibers on the interior of the felt.

The hat body is put in the dye and brought up to a boil from 120 F. andboiled one-half hour. To drive the dye from the liquor,- five per centof acetic acid (56%) is added to the dye solution and the hatbodies'boiled from to minutes more, then five per cent of formic acid(85%) is added to the solution and a further boiling of 10 to 20 minutestakes place. In dark hats, three per cent of sulphuric acid may be addedand the bodies boiled an additional 10 to 20 minutes. The hats are thenfinished in the usual manner.

The resin coating on the cotton fibers is not washed off by the use ofthe hot water during the working up of the hat body or by the boiling inthe acids. Its afilnity for acid dye is not impaired by the hightemperatures necessary during the felting and dyeing so that in the hatbody resulting from this process the fur on the exterior of the felt andthe center-seeking cotton in the interior of the felt are both uniformlydyed the same color. These hats present the highly desirable appearanceand feel of an all-fur felt hat.

While we have described the making of a hat, it is to be understood thatthe present invention is applicable to any felt product embodying animaland nonanimal fibers which is to be dyed.

Variations and modifications may be made within the scope of thisinvention and portions of the improvements may be used without others.

We claim:

1. In the method of making a dyed felt hat, the steps of conditioningfur fibers for felting; dyeing, with fast colors unaffected by asubsequent treatment, combed cotton flb$ $9 9. 99 9i of the fur withwhich it is to be used; subjecting the cotton fibers to a singlechemical treatment with a solution of 2%10% melamine, 4%-9% hydrochloricacid (32%), 4%-10% formaldehyde, .5%-2% of a softener and the balancewater, to simultaneously impart center-seeking characteristics theretoand to provide a coating on said fibers receptiveof .acid dye; mixingsaid fur and cotton fibers; forming the mixed fibers into a hat bodyhaving the fur fibers on the exterior and the cotton fibers in thecenter of the felt; and dyeing the hat body with an acid dye to colorsaid furfibers and the coating on said cotton fibers.

2. In the method of making a dyed fabric, the steps of conditioninganimal fibers for felting; treating nonanimal fibers with a solution of2%- 10% melamine, 4%-9% hydrochloric acid (32%), 4%-l0% formaldehyde, .5%2% of a softener and the balance water, to impart center-seekingcharacteristics thereto and to provide a surface on said fibersreceptive of acid dye; drying the fibers at between 190195 F.; mixingsaid fur and treated nonanimal fibers; felting the mixed fibers into acomposite fabric having the animal fibers on the exterior and thenonanimal fibers in the center of the felt; and dyeing the compositefelt with an acid dye at temperatures up to 212 F.

3. In the method of making a dyed hat, the steps of conditioning furfibers for felting; thoroughiy cleaning the surface of combed cottonfibers to remove surface deposits therefrom; treating the cotton fiberswith a solution of 2%- 10% melamine, 4%-9% hydrochloric acid (32%),4%-10% formaldehyde, .5%2% of a. softener and the balance water, toimpart center-seeking characteristics thereto and to provide a surfaceon said fibers receptive of acid fur dye; drying the fibers at between190-195 F.; mixing said fur and treated cotton fibers; forming the mixedfibers, into a bat; subjecting the bat to hot water and pressure to feltit into a hat body having the fur fibers on the exterior and the cottonfibers in the center of the felt; and dyeing the composite felt with anacid fur dye at temperatures between 200-212 F.

4. In the method of making a dyed hat, the steps of conditioning furfibers for felting; treating cotton fibers with an aged solution of2%10% -melamine, 4%-9% hydrochloric acid (32%), 4%-

l0% formaldehyde (35-40%), .5-2% of a softener and the balance water toimpart center-seeking characteristics thereto and to provide a surfaceon said fibers receptive of acid fur dye; drying the fibers at between190195 F.; mixing said fur and treated cotton fibers; forming the mixedfibers into a hat body having the fur fibers on the exterior and thecotton fibers in the center of the felt; and dyeing the composite feltwith an acid fur dye at temperatures up to 212 F.

5. In the method of making a dyed hat, the

7 steps of conditioning fur fibers for felting; treating cotton fiberswith an aged solution of 5% rmelamine, 6% hydrochloric acid (32%), 8%

formaldehyde (35-40%), 1% of a softener and the balance water to impartcenter-seeking 'characteristics thereto and to provide a surface on saidfibers receptive of acid fur dye; drying the fibers at between -195 F.;mixing said fur and treated cotton fibers; forming the mixed fibers intoa hat body having the fur fibers on the exterior and the cotton fibersin the center "of the felt; and dyeing the composite felt with an acidfur dye at temperatures up to 212 F.

' amine, 4%9% 6. A felt hat body having inner and outer sur facesections of fur fibers, and an intermediate section of cotton fibersbetween said surface sections, said cotton fibers having a surfacederived from an aged, aqueous solution of 2%-10% melamine, 4%-9%hydrochloric acid, 4%10% formaldehyde and .5%-2% of a softener, saidfibers having interior-seeking characteristics when mixed with the furfibers and being receptive of acid dye, some of the fur and cottonfibers at the contacting faces of adjacent sections being intermingledand interfelted to provide a composite inseparable felt, the compositefelt being dyed with acid dye.

'7. A felt hat body having inner and outer surface sections of furfibers, and an intermediate section of rayon fibers between said surfacesections, said rayon fibers having a surface derived from an aged,aqueous solution of 2% melamine, 4%-9% hydrochloric acid, 4%-10%formaldehyde and .5%2% of a softener, said fibers havinginterior-seeking characteristics when mixed with the fur fibers andbeing receptive of acid dye, some of the fur and rayon fibers at thecontacting faces of adjacent sections being intermingled and interfeltedto provide a composite inseparable felt, the composite felt being dyedwith acid dye.

8. A felt hat body having inner and outer surface sections of animalfibers, and an intermediate section of nonanimal fibers between saidsurface sections, said nonanimal fibers having a surface derived from asolution of 2%-10% melhydrochloric acid (32%), 4%-10% formaldehyde,.5%-2% of a softener and the balance water, said fibers havinginteriorseeking characteristics when mixed with the animal fibers andbeing receptive of acid dye, some of the animal and nonanimal fibers atthe contacting faces of adjacent sections being intermingled andinterfelted to provide a composite inseparable felt, the composite feltbeing dyed with acid dye.

9. A felt fabric body having inner and outer surface sections of animalfibers, and an intermediate section of nonanimal fibers between saidsurface sections, said nonanimal fibers having a 6 surface derived froman aged aqueous solution of 2%-10% melamine, 4%-9% hydrochloric acid,4%-10% formaldehyde, and .5%-2% of a softener, the nonanimal fibershaving interior-seeking characteristics when mixed with the animalfibers and being receptive of acid dye, some of the animal and nonanimalfibers at the contacting faces of adjacent sections being intermingledand interfelted to 'provide a composite inseparable felt, the compositefelt being dyed with acid dye.

10. A feltable fiber for use with animal fibers in dyed felt comprisingchemically treated nonanimal fibers having a resinous coating thereonderived from a, solution of 2%10% melamine, 4%-9% hydrochloric acid(32%) 4%10% formaldehyde, .5%-2% .of a softener and the balance water,with a strong affinity for acid dye, said coating being insoluble inwater or acid at temperatures up to 212 F. g

11. A feltable fiber for use with animal fibers in dyed felt comprisingcotton fiber having a surface thereon derived from an aqueous solutionof 4%9% hydrochloric acid, 2%10% melamine, 4%-10 formaldehyde (35%-40%)and .5%-2% of a softener, said fiber having center seekingcharacteristics when mixed with animal fiber and an affinity for aciddye.

GEORGE M. RICKUS. STANLEY G. HOFFMAN. BERNARD H. ARCHER.

REFERENCES CITED The following references are of record in the

